Systems and methods for providing, in programmable motion devices, compliant end effectors with noise mitigation

ABSTRACT

A vacuum cup is disclosed for use in a programmable motion device. The vacuum cup includes an open inlet for coupling to a vacuum source, and a vacuum cup lip on a portion of the vacuum cup that generally surrounds the open inlet. The vacuum cup lip includes an inner surface that defines the open outlet through which a vacuum may be provided, and includes noise mitigation features on an outer surface of the vacuum cup lip.

PRIORITY

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/884,359 filed Aug. 8, 2019, the disclosure ofwhich is hereby incorporated by reference in its entirety.

BACKGROUND

The invention generally relates to programmable motion systems andrelates in particular to end-effectors for programmable motion devices(e.g., robotic systems) for use in object processing such as objectsortation or order fulfillment.

End-effectors for robotic systems may be employed, for example, incertain applications to select and grasp an object, and then move theacquired object very quickly to a new location. End-effectors should bedesigned to quickly and easily select and grasp an object from a jumbleof dissimilar objects, and should be designed to securely grasp anobject during movement. Certain end-effectors, when used on differentobjects of different physical sizes, weights and materials, may havelimitations regarding how securely they may grasp an acquired objectduring rapid movement, particularly rapid acceleration and deceleration(both angular and linear).

Many end-effectors employ vacuum pressure for acquiring and securingobjects for transport and/or subsequent operations by robotic systemsthat include articulated arms. Other techniques for acquiring andsecuring objects involve electrostatic attraction, magnetic attraction,needles for penetrating objects such as fabrics, fingers that squeeze anobject, hooks that engage and lift a protruding feature of an object,and collets that expand in an opening of an object, among othertechniques.

In applications where vacuum pressure is used to acquire and secureobjects, an end-effector may include a vacuum cup having a compliant lipthat contacts the object to be grasped. The compliant lip may be formedof a polymeric or elastomeric material that is flexible enough to allowit to adapt to variations in surface structures. The lip may facilitatecreating a seal with a surface despite irregularities such as bumps andtexture on the surface. The flexibility allows the vacuum cup to conformto the shape of objects or to wrap around corners of objects to createan adequate seal for acquiring and securing the object.

When a good seal is not created between a flexible vacuum cup and anobject however, (due for example, to the nature of the product orbecause the vacuum cup is overhanging an edge of the object), theportion of the lip of the vacuum cup that is not well sealed maycontribute to making noise, sometimes a substantial amount of noise, andthe noise level may be above safe limits if human personnel are in closeproximity to the programmable motion device. Other types ofend-effectors, however, including vacuum cups with less flexible lips(in addition to those using electrostatic attraction, magneticattraction, needles for penetrating objects such as fabrics, fingersthat squeeze an object, hooks that engage and lift a protruding featureof an object, and collets that expand in an opening of an object), areless effective at acquiring and moving a wide variety of objects.

There remains a need therefore, for an end-effector system in aprogrammable motion system that may select and grasp any of a widevariety of objects, and then move the acquired objects very quickly to anew location while not producing an unacceptable level of noise.

SUMMARY

In accordance with an aspect, the invention provides a vacuum cup foruse in a programmable motion device. The vacuum cup includes an openinlet for coupling to a vacuum source, and a vacuum cup lip on a portionof the vacuum cup that generally surrounds the open inlet. The vacuumcup lip includes an inner surface that defines the open outlet throughwhich a vacuum may be provided, and includes noise mitigation featureson an outer surface of the vacuum cup lip.

In accordance with another aspect, the invention provides a vacuum cupfor use in a programmable motion device. The vacuum cup includes an openinlet for coupling to a vacuum source, a vacuum cup lip on a portion ofthe vacuum cup that is generally opposite the open inlet, and an openoutlet through which a vacuum may be provided. The vacuum cup includes aplurality of protrusions on an outer surface of the vacuum cup lip.

In accordance with yet another aspect, the invention provides a methodof providing a vacuum source in a programmable motion device. The methodincludes coupling the vacuum source to open inlet of a vacuum cup, saidvacuum cup including noise mitigation features on an outer surface ofthe vacuum cup, and providing a vacuum cup open outlet through which thevacuum may be provided.

In accordance with a further aspect, the invention provides a system forproviding automated processing of objects. The system includes aprogrammable motion device including an end-effector that is coupled toa vacuum source. The end-effector includes a vacuum cup that includesnoise mitigation features on an outer surface of the vacuum cup.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIG. 1 shows an illustrative diagrammatic view of an automated objectprocessing system in accordance with an aspect of the present invention;

FIG. 2 shows an illustrative diagrammatic view of an underside of anend-effector in accordance with an aspect of the invention that ispartially grasping an object;

FIGS. 3A and 3B show illustrative diagrammatic views of a vacuumend-effector in accordance with the prior art from a side view (FIG. 3A)and from below (FIG. 3B);

FIGS. 4A and 4B show an illustrative diagrammatic partial side views ofa portion of a vacuum cup lip initially overhanging an object (FIG. 4A),and subsequently undergoing resonance causing noise (FIG. 4B);

FIG. 5 shows an illustrative diagrammatic view of an end-effector foruse in an automated object processing system in accordance with anaspect of the invention that includes pairs of noise mitigationfeatures;

FIG. 6 shows an illustrative diagrammatic view of an end-effector foruse in an automated object processing system in accordance with anotheraspect of the invention including larger noise mitigation features;

FIG. 7 shows an end-effector for use in an automated object processingsystem in accordance with another aspect of the invention including setsof three noise mitigation features;

FIG. 8 shows an end-effector for use in an automated object processingsystem in accordance with an aspect of the invention includingwedge-shaped noise mitigation features;

FIGS. 9A and 9B show an end-effector for use in an automated objectprocessing system in accordance with an aspect of the inventionincluding cylindrical-shaped noise mitigation features from above (FIG.9A) and from below (FIG. 9B);

FIG. 10 shows an illustrative diagrammatic partial side view of theend-effector of FIG. 5;

FIG. 11 shows an illustrative diagrammatic underside view of theend-effector of FIG. 9B while undergoing resonance; and

FIG. 12 shows an illustrative diagrammatic underside view of anend-effector in accordance with an aspect of the present invention thatincludes large semi-spherical protrusions as noise mitigation features.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

In high airflow vacuum applications, a vacuum is provided that has anairflow of at least about 100 cubic feet per minute, and a vacuumpressure at the end effector of no more than about 65,000 Pascals belowatmospheric (e.g., about 50,000 Pascals below atmospheric or 7.25 psi).Applicants have discovered that when such a high airflow vacuum isprovided that does not create a good seal (again, due for example to thenature of the product or because the vacuum cup overhangs an edge of theobject), the lip may vibrate from the high airflow creating a loud(sometimes whistling) noise.

In accordance with various aspects, the invention provides a vacuum cupfor a programmable motion device that include integral noise mitigationfeatures. In accordance with further specific aspects, the noisemitigation features may include any of protrusions, lands, rises, relieffeatures, and/or bumps that extend from a non-object contacting side ofthe lip of a vacuum cup. Surprisingly, the use of such features reducesthe noise generated by a compliant vacuum cup when used in a highairflow application.

In accordance with various aspects, the noise mitigation featuresincrease the mass of the vacuum cup on the outer rim, but do notnegatively decrease the flexibility of the material of the vacuum cuplip. Such noise mitigation features are believed to reduce the frequencyat which the vacuum cup lip vibrates when subject to the high vacuumflowrate, while not adversely affecting the stiffness of the vacuum cuplip, which is important to providing the compliance (flexibility) neededto create a seal in a wide variety of applications.

The invention involves adding material to a top side of a lip of amolded vacuum cup, which may be presented as small protrusions or bumps(features) encircling the top side of the lip of the cup in accordancewith various aspects. The distance between each of the features, as wellas the circumference(es) and height(s) and/or length(s), width(s), andheight(s) of the features may vary in accordance with various aspects,together with the material of the vacuum cup lip, the thickness of thelip of the cup and the size (diameter) of the circumference of thecenters of the circle of features, as well as the angle (complex orlinear) of the widening of the lip of the vacuum cup within bounds ofvarious aspects of the invention that provide sufficient flexibility toengage a good seal on a variety of objects, yet also provide asufficient quantity of sufficiently distributed outer mass features onthe top side of a lip of a vacuum cup.

For example, a vacuum cup of an end effector may have an innermostdiameter (vacuum passage) of about 0.5 inches to about 1.5 inches, whilea lip of the vacuum cup may have an outer diameter of about 1.5 inchesto about 4.5 inches. A high flow vacuum may be provided, e.g., by ablower, having a vacuum pressure at the end effector of no more thanabout 65,000 Pascals below atmospheric (e.g., about 50,000 Pascals belowatmospheric or 7.25 psi).

FIG. 1 for example, shows a system 10 including a programmable motiondevice 12 having an end effector 14 in accordance with an aspect of thepresent invention. A vacuum source 16 is coupled to the end effector 14via a hose 18, and the programmable motion device 12 is programmed toselect objects 20, 22, 24 from an input area 26 (including for example abelted conveyor 28), and to provide selected objects to an output area30 that includes, for example, one or more output boxes 32 under thecontrol of one or more computer processing systems 34. Operation of theprogrammable motion device (e.g., robot) 12, including for example,current jobs and future intended movements or needs of the robot 12, maybe displayed on a monitor 36, and an override stop switch 38 may also beprovided for safety purposes.

FIG. 2 shows an underside of a vacuum cup 40 of the end effector 14,wherein the vacuum cup 40 is grasping an object 42 such that a seal isnot formed against the object because the vacuum cup extends over anedge of the object. Using the high flow vacuum of embodiments of thepresent invention (e.g., about 50,000 Pascals below atmospheric), theobject is grasped and maintained by the vacuum cup.

FIGS. 3A and 3B show a vacuum cup 50 in accordance with the prior art.The vacuum cup 50 includes an attachment portion 52 for attaching to anend effector section, a flexible bellows portion 54, and a flexibleflanged portion 56 for creating a seal against objects. The innersurface of the flexible flanged portion 56 includes ribs 58 spacedradially inward of an outer lip 59 of the vacuum cup. The ribs 58support the flanged portion (i.e., keep the flanged portion fromcollapsing onto an object), when under the force of a sealed vacuumagainst an object.

With reference to FIGS. 4A and 4B, when a seal is not created by the endvacuum cup 50 on an object 42 (e.g., because the object is grasped nearan edge of the object), although the object may be able to be lifted bythe force of the high flow vacuum passing between the ribs 58 (as shownin FIG. 4A), the overhanging portion of the vacuum cup lip 59 may bedrawn toward the object 42 (as shown in FIG. 4B). Under selectcircumstances (e.g., the flexibility/stiffness of the flexible lip, thethickness of the flexible lip, the air flow rate, and the shape andvolume of the open area that is not contacting the object), the vacuumcup lip may vibrate, causing substantial noise.

FIG. 5 shows a vacuum cup 60 in accordance with an aspect of the presentinvention. The vacuum cup 60 includes an attachment portion 62 forattaching to an end effector section, a flexible bellows portion 64, anda flexible flanged portion 66 for creating a seal against objects. Theinner surface of the flexible flanged portion 66 includes ribs 67 spacedradially inward of an outer lip 69 of the vacuum cup. The vacuum cup 60further includes noise mitigation features 68 in the form of partialspheres that are spaced from one another along a circumference of thevacuum cup lip. The noise mitigation features may be formed of, forexample, silicone adhesive. The noise mitigation features may be evenlyspaced with respect to the ribs 67 such that two features are provided(on the top) between ribs (on the bottom).

FIG. 6 shows a vacuum cup 70 in accordance with another aspect of thepresent invention that includes single, larger features associated withribs. Similarly, the vacuum cup 70 includes an attachment portion 72 forattaching to an end effector section, a flexible bellows portion 74, anda flexible flanged portion 76 for creating a seal against objects. Theinner surface of the flexible flanged portion 76 includes ribs 77 spacedradially inward of an outer lip 79 of the vacuum cup. The vacuum cup 70further includes noise mitigation features 78 in the form of fewerlarger spheres than the embodiment of FIG. 5 that are spaced from oneanother along a circumference of the vacuum cup lip. The noisemitigation features may be formed of, for example, silicone adhesive.The noise mitigation features may be evenly spaced with respect to theribs 67 such that one feature is provided (on the top) between ribs (onthe bottom).

FIG. 7 shows a vacuum cup 80 in accordance with a further aspect of thepresent invention that incudes differently sized features. The vacuumcup 80 includes an attachment portion 82 for attaching to an endeffector section, a flexible bellows portion 84, and a flexible flangedportion 86 for creating a seal against objects. The inner surface of theflexible flanged portion 86 includes ribs 87 spaced radially inward ofan outer lip 89 of the vacuum cup. The vacuum cup 80 further includesnoise mitigation features 85, 88 in the form of spheres that are spacedfrom one another along a circumference of the vacuum cup lip. The noisemitigation features may be formed of, for example, silicone adhesive.The noise mitigation features may be evenly spaced with respect to theribs 87 such that three features of two different sizes are provided (onthe top) between ribs (on the bottom).

FIG. 8 shows a vacuum cup 90 in accordance with another aspect of thepresent invention that includes edge-shaped features. Similarly, thevacuum cup 90 includes an attachment portion 92 for attaching to an endeffector section, a flexible bellows portion 94, and a flexible flangedportion 96 for creating a seal against objects. The inner surface of theflexible flanged portion 96 includes ribs 97 spaced radially inward ofan outer lip 99 of the vacuum cup. The vacuum cup 90 further includesnoise mitigation features 98 in the form of wedges that are spaced fromone another along a circumference of the vacuum cup lip. The noisemitigation features may be formed of, for example, silicone adhesive.The noise mitigation features may be evenly spaced with respect to theribs 97 such that one feature is provided (on the top) between ribs (onthe bottom).

FIGS. 9A and 9B show a vacuum cup 100 in accordance with a furtheraspect of the present invention that includes cylindrically-shapedfeatures. The vacuum cup 100 includes an attachment portion 102 forattaching to an end effector section, a flexible bellows portion 104,and a flexible flanged portion 106 for creating a seal against objects.The inner surface of the flexible flanged portion 106 includes ribs 107spaced radially inward of an outer lip 109 of the vacuum cup. The vacuumcup 100 further includes noise mitigation features 108 in the form ofcylinders that are spaced from one another along a circumference of thevacuum cup lip. The noise mitigation features may be formed of, forexample, silicone adhesive. The noise mitigation features may be evenlyspaced with respect to the ribs 107 such that two features are provided(on the top side) between ribs (on the bottom side).

With further reference to FIG. 10, in accordance with the above aspectsof the present invention, when a seal is not made between a vacuum cup(e.g., 60) and an object 42, the noise mitigation features (e.g., 68)near the vacuum cup lip (e.g., 69) dampen the vibration of the vacuumcup lip, significantly reducing noise. Each of the noise mitigationfeatures also discussed above (e.g., 68, 78, 85, 88, 98) may functionsimilarly to reduce noise. Further, certain types of noise mitigationfeatures (such as those discussed above with respect to FIGS. 9A and9B), may contact each other as shown in FIG. 11 when the lip movesinward due to a high vacuum flow, further contributing to noisemitigation.

The noise mitigation features may, for example, range from about 0.008cubic centimeters to about 1.75 cubic centimeters, and may preferablyeach be less than about 1 cubic centimeter in volume in certainembodiments. The noise mitigation features may also be formed of any ofa silicone based adhesive, epoxy-based adhesive, or other polymericmaterial.

FIG. 12 shows vacuum cup similar to that of FIG. 6 with larger noisemitigation features. In particular, FIG. 12 shows a vacuum cup 110 inaccordance with another aspect of the present invention that includeslarger partial spherically-shaped features. Similarly, the vacuum cup110 includes an attachment portion 112 for attaching to an end effectorsection, a flexible bellows portion 114, and a flexible flanged portion116 for creating a seal against objects. The inner surface of theflexible flanged portion 116 includes ribs 117 spaced radially inward ofan outer lip 119 of the vacuum cup. The vacuum cup 110 further includeslarger noise mitigation features 118 in the form of large spheres thatare spaced from one another along a circumference of the vacuum cup lip.The noise mitigation features may be formed of, for example, siliconeadhesive. The noise mitigation features may be evenly spaced withrespect to the ribs 117 such that one feature is provided (on the top)between ribs (on the bottom).

In accordance with various embodiments therefore, the invention providesa system for providing automated processing of objects, where the systemincludes a programmable motion device including an end effector that iscoupled to a vacuum source, with the end effector including a vacuum cupthat includes noise mitigation features on an outer surface thereof.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments withoutdeparting from the spirit and scope of the present invention.

What is claimed is:
 1. A vacuum cup for use in a programmable motiondevice, said vacuum cup comprising an open inlet for coupling to avacuum source, and a vacuum cup lip on a portion of the vacuum cup thatgenerally surrounds the open inlet, said vacuum cup lip including aninner surface that defines the open outlet through which a vacuum may beprovided, and including noise mitigation features on an outer surface ofthe vacuum cup lip.
 2. The vacuum cup as claimed in claim 1, whereinvacuum cup lip is formed of a flexible polymeric material.
 3. The vacuumcup as claimed in claim 1, wherein said noise mitigation features areformed of a polymeric material.
 4. The vacuum cup as claimed in claim 1,wherein vacuum cup lip is formed of a flexible polymeric material. 5.The vacuum cup as claimed in claim 1, wherein said noise mitigationfeatures encircle the vacuum cup lip in a discontinuous manner.
 6. Thevacuum cup as claimed in claim 1, wherein said noise mitigation featuresinclude protrusions from the vacuum cup lip on the outer surface of thevacuum cup lip.
 7. The vacuum cup as claimed in claim 6, wherein saidprotrusions are positioned alternate internal ribs on an inner surfaceof the vacuum cup lip.
 8. The vacuum cup as claimed in claim 1, whereinsaid vacuum cup includes a flexible bellows portion.
 9. The vacuum cupas claimed in claim 1, wherein said vacuum cup is generally conicallyshaped.
 10. A vacuum cup for use in a programmable motion device, saidvacuum cup comprising an open inlet for coupling to a vacuum source, avacuum cup lip on a portion of the vacuum cup that is generally oppositethe open inlet, and a vacuum cup open outlet through which a vacuum maybe provided, said vacuum cup including a plurality of protrusions on anouter surface of the vacuum cup lip.
 11. The vacuum cup as claimed inclaim 10, wherein vacuum cup is formed of a flexible polymeric material.12. The vacuum cup as claimed in claim 10, wherein said plurality ofprotrusions are formed of a polymeric material.
 13. The vacuum cup asclaimed in claim 10, wherein vacuum cup is formed of a flexibleelastomeric material.
 14. The vacuum cup as claimed in claim 10, whereinsaid plurality of protrusions encircle the vacuum cup open outlet in adiscontinuous manner.
 15. The vacuum cup as claimed in claim 10, whereinsaid plurality of protrusions include at least partially generallyspherical protrusions.
 16. The vacuum cup as claimed in claim 15,wherein said plurality of protrusions are positioned alternate internalribs on an inner surface of the vacuum cup lip.
 17. The vacuum cup asclaimed in claim 10, wherein said vacuum cup includes a flexible bellowsportion.
 18. The vacuum cup as claimed in claim 10, wherein said vacuumcup is generally conically shaped.
 19. The vacuum cup as claimed inclaim 10, wherein the plurality of protrusions provide that the vacuumcup lip includes alternating areas of relatively thin and relativelythicker lip thicknesses.
 20. A method of providing a vacuum source in aprogrammable motion device, said method comprising: coupling the vacuumsource to open inlet of a vacuum cup, said vacuum cup including noisemitigation features on an outer surface of the vacuum cup; and providinga vacuum cup open outlet through which the vacuum may be provided. 21.The method as claimed in claim 20, wherein said noise mitigationfeatures are formed of a polymeric material.
 22. The method as claimedin claim 20, wherein said noise mitigation features are formed of anelastomeric material.
 23. The method as claimed in claim 20, whereinsaid noise mitigation features encircle the vacuum cup open outlet in adiscontinuous manner.
 24. The method as claimed in claim 20, whereinsaid noise mitigation features include protrusions from the vacuum cupon the outer surface of the vacuum cup.
 25. The method as claimed inclaim 24, wherein said protrusions are positioned alternate internalribs on an inner surface of the vacuum cup.
 26. The method as claimed inclaim 20, wherein said vacuum cup includes a flexible bellows portion.27. The method as claimed in claim 20, wherein said noise mitigationfeatures alter a resonance of the open outlet of the vacuum cup.
 28. Themethod as claimed in claim 20, wherein the method further includesdamping a resonance of a lip of the vacuum cup while the vacuum isprovided through the open outlet.
 29. The method as claimed in claim 28,wherein the method further includes providing a vacuum pressure at theend effector of no more than about 50,000 Pascals below atmospheric 30.A system for providing automated processing of objects, said systemcomprising a programmable motion device including an end effector thatis coupled to a vacuum source, said end effector including a vacuum cupthat includes noise mitigation features on an outer surface of thevacuum cup.
 31. The system as claimed in claim 30, wherein said noisemitigation features encircle a vacuum cup lip in a discontinuous manner.32. The system as claimed in claim 30, wherein said noise mitigationfeatures include protrusions from a vacuum cup lip on the outer surfaceof the vacuum cup.
 33. The system as claimed in claim 32, wherein saidprotrusions are positioned alternate internal ribs on an inner surfaceof the vacuum cup.
 34. The system as claimed in claim 30, wherein saidvacuum cup includes a flexible bellows portion.
 35. The system asclaimed in claim 30, wherein the vacuum source provides a maximum airflow rate at the end effector of at least about 100 cubic feet perminute.
 36. The system as claimed in claim 30, wherein the vacuum sourceprovides a vacuum pressure at the end effector of no more than about50,000 Pascals below atmospheric.